Page 263 - Improving Machinery Reliability

234 Improving Machinery Reliability

Machinery audit functional checklist. (Continued)
3. Responsibility/Authority (Boundaries of IV. Spare Parts Availability/Quality Control
Jurisdiction) Function
a) MissioniRole Statements A. Organization
b) Horizontal (Across Functions) 1. Structure
c) Vertical (Hierarchy) a) Plant-wide
d) Understanding (Communicated) b) Relationships: MTS, Process, Techni-
4. Training-Initial/Continuing cal, Maintenance, Purchasing, Stores
a) Scope (Classroom, On-The-Job) 2. Manning for Routine & Special Spares,
b. FaciliteslResources Le., New and Rebuilds
c) Contractor Qualifications~raining a) In-house/Contract Inspection and
B. Standard Maintenance Procedures Expediting
1. Routine Tasks and Actions 3. ResponsibilitylAuthority
a) Testing of AuxiliarylSackup and Pro- a) MissionRole Statements (Materials
tective Systems Management Policy)
b) Parts Availability Verification and b) Definition of Parts Needs, Initial and
Quality Control Restocking
c) Other, e.g., Vibration Signature c) Inventory Control
Analysis, Oil Condition, Seal Oil B. Procedures and Systems
Leakage Rates 1. Purchase Order Preparation
2. Turnaround Planning a) Routine Spares-Automatic
a) Organization Reordering
b) Procedure for Development b) Special Request Spares-Rebuilds,
c) Machinery System Coordination T/A Preordering
d) Backlog Review 2. Inspection and Expediting Procedures
3. Emergency a) Schedule, Quality, Deviation from
C. Systems in Place P.O.
1. Inspection Tools/Techniques Available 3. Material Received Acknowledgement
and Used 4. Material Received Inspection
2. Preventive/Predictive 5. Special Storage Requirements
3. New, Small Expansion Project Respon- 6. Intra- and Inter-plant Interchangeability
sibilities 7. Inventory Control

Typical Findings are Discussed with Plant Personnel

As was indicated earlier, the findings and recommendations of a rigorous machin-
ery reliability audit are always discussed with local management and/or other desig-
nated personnel before the audit team leaves the site. These discussions enable all
attendees to hear and question the team’s assessment. Better yet, the discussion pro-
vides an excellent forum for debate and discourse, allowing all concerned parties an
opportunity to “buy into” the conclusions and recommendations.
The results of a typical machinery audit are often presented with three areas of
emphasis. These areas deal with operational practices and procedures influencing
reliability, machinery impact on reliability, and organizational means for improving
reliability. Follow-up material compiled and forwarded by the audit team generally
includes a series of supporting documents designed to aid in implementing better
control of machine reliability through organizational, mechanical, and procedural
means. This “appendix package” typically includes documents such as a specific role
statement for important machinery-related engineering positions, sample procedures
for the performance of critical instrument on-stream inspection, improved startup